Thanks Dan,

Are mostly falling off doors normal on Discovery's? I've heard bad bad - oh so bad - things about Freelanders but thought the Discovery's were a bit better...
Depends who you ask, Hippo would tell you Discoveries are worserer but he's full of ****e :D:D:D

Out here on the west coast everything rusts to bits so it's to be expected.

Your flange looks good :eek:
 
Ye gads - another milestone moment - I put something together today.

1965 series 2a station wagon fitting first UJ to front propshaft1.JPG
1965 series 2a station wagon fitting first UJ to front propshaft2.JPG
1965 series 2a station wagon fitting first UJ to front propshaft3.JPG
1965 series 2a station wagon fitting first UJ to front propshaft4.JPG


And look! I didn't even forget to position the grease nipple in the correct place so the UJ can be serviced. (Not mentioned in ye olde greene booke)

Still got to order the front part to see if I can get some better fitting splines...
 
Even had 10 minutes of scraping.

Nasty horse hair on the underside of the safari roof needs to come off. I tried burning / heating and - holy **** - that horse hair goes off like a bush fire!

So - I opted for some paint stripper.

[IN THE OLD DAYS RANT]

You used to be able to get paint stripper that actually worked. Now we're stuck with utter crap that really ought to have the manufacturer's in daily trouble with trading standards. I mean even Nitromores is rubbish these days...

...still one solution which sort of kinda works at a silly price is POR strip

[/IN THE OLD DAYS RANT]

1965 series 2a station wagon removing bitumastic sound deadening goo1.JPG
1965 series 2a station wagon removing bitumastic sound deading goo2.JPG
1965 series 2a station wagon removing bitumastic sound deadening goo3.JPG
 
You can still get proper paint stripper but you technically need to be in the trade. autojumbles you can get it but be aware of cheap stuff as it does have a shelf life and should have an expiry date on it, if it doesn't then it may be a bit crap. I think you need to phone them order it. due to crapness of my super whizzo smartphone I cannot post a link so do a search for origiplate and they should be the first one in the list.
 
Well thanks for the suggestion. I'll see if they'll post to Holland.

(Probably not - for some reason they often say couriers won't take chemical products across a little bit of water - must be because they employ so many witches - they of course have trouble crossing water...)

I had an in the olde days rant about red oxide just last week!

Well I'm glad I'm not the only one ranting about stuff.

You can still get proper paint stripper but you technically need to be in the trade. autojumbles you can get it but be aware of cheap stuff as it does have a shelf life and should have an expiry date on it, if it doesn't then it may be a bit crap. I think you need to phone them order it. due to crapness of my super whizzo smartphone I cannot post a link so do a search for origiplate and they should be the first one in the list.

Yep once you've invented the bomb you can't un-invent it - I've tried getting the decent stuff through "professional" people I know but even they have to provide so much health and safety paper work they can't be bothered with it!
 
Had some time to get the first of the front hubs underway

1965 series 2a station wagon front hub derust and bearing replace1.JPG


The bearings are not quite toast yet but they've been living in muck ****e for so long the running surfaces are a bit past it. A bit of discolouration which is difficult to tell if it is due to over heating or just muck.

1965 series 2a station wagon front hub derust and bearing replace2.JPG


1965 series 2a station wagon front hub derust and bearing replace3.JPG


1965 series 2a station wagon front hub derust and bearing replace4.JPG


Nice time masking!

1965 series 2a station wagon front hub derust and bearing replace5.JPG


For the parts that aren't mega rusty and need to sit in a bath of Rustyco I'm speeding things along with Brunox. It is a weird epoxy thing that comes out of the can in a clear fluid. It reacts to rust and turns it black and seals in one go.

I'll be undercoating a second layer with ferpox undercoat too (overkill) and then using the chassis black top coat.
1965 series 2a station wagon front hub derust and bearing replace6.JPG
 
Front hub continued...

...Ferpox undercoat went on over the Brunox

1965 series 2a station wagon ferpox coating on front wheel hub steering arm and drive flange.JPG


I then fitted the bearing cups using the old bearing wrapped in masking tape to help press the bearing cup in place.

1965 series 2a station wagon front hub derust and bearing replace7.JPG


1965 series 2a station wagon front hub derust and bearing replace8.JPG


1965 series 2a station wagon front hub derust and bearing replace9.JPG


Last Ferpox undercoating to get rid of the scrape marks left from fitting the bearing cups

1965 series 2a station wagon front hub derust and bearing replace10.JPG


(Differential on the RHS - more about that in the following posts)
 
After the corrosion problems with the differential I ended up buying a second hand one. 63 euros delivered. Turned out to be a pretty good deal. I pulled it to bits to check the condition and it looks like only the pinion bearings need to be replaced. Happy days!

It isn't a series 2a differential, however, it is a series 3. Nearly the same - not quite - anyone know all the differences? (answers on a post card etc)

1965 series 2a station wagon replacement front differential1.JPG


Instead of wire locking on the axial bearing caps running through the clamps for the axial adjusting "wheels" there's just a split pin

1965 series 2a station wagon replacement front differential2.JPG


I wanted to replace the pinion seal at the very least and I hoped the pinion bearings would be good

1965 series 2a station wagon replacement front differential3.JPG


Not shown in the pictures but the pinion bearings show signs of over heating

1965 series 2a station wagon replacement front differential4.JPG


1965 series 2a station wagon replacement differential5.JPG


Axial bearings in acceptable condition - so they will stay

1965 series 2a station wagon replacement front differential6.JPG


De-rusting the casing

1965 series 2a station wagon replacment front differential7.JPG


Also after angle grinder and wire brush attachment

1965 series 2a station wagon replacement front differential8.JPG


Rustyco gel treatment for a few hours =>

1965 series 2a station wagon replacement front differential9.JPG


Pulling large bearing off the pinion

1965 series 2a station wagon replacment front differential10.JPG


Re-position your puller when you get more space!

1965 series 2a station wagon replacement front differential11.JPG


De-rusting done - only small areas with light rust in those hard to reach areas. Treated with Brunox - and now over (under) coated with Ferpox

1965 series 2a station wagon replacement front differential12.JPG
 
Bad news

1 X king pin buggered

1 X front half shaft arsed up with rust too

(I guess the other side are just as bad)

View attachment 103396 View attachment 103397 View attachment 103398
I have had much the same problems. I needed replacement outer part of both halfshafts. The first few places I looked all wanted £100+. Paddocks only wanted approx. £22 per side. Not sure if it was an up-cock on their website but they have arrived and are Bearmach parts. Happy days.
 
I have had much the same problems. I needed replacement outer part of both halfshafts. The first few places I looked all wanted £100+. Paddocks only wanted approx. £22 per side. Not sure if it was an up-cock on their website but they have arrived and are Bearmach parts. Happy days.
I found the outer shaft on paddocks for the price you mention. Looks fine to me. The larger inner half shafts are blinking expensive though...

...I think I'll try and find a good second hand solution first.
 
Not much progress today

Does anyone know the name of the colour painted on these engine parts?

1965 series 2a station wagon diesel engine breather and fill cap assembly.JPG


The breather pipe on the engine is obviously black but the filler / breather cap looks like it was once a cream colour.

1965 series 2a station wagon diesel engine oil filler and breather cap1.JPG


1965 series 2a station wagon diesel engine oil filler and breather cap2.JPG


The same colour seems to have been used on the oil filter assembly too

1965 series 2a station wagon diesel engine oil filter housing.JPG
 
1965 series 2a station wagon rust removed from engine oil filler breather pipe.JPG


The pipe for the combined breather and the oil fill thing is now in VHT caliper paint satin black. I hope it stays stuck on!

Weather here has not been paint friendly. The humidty is a tad on the damp side (sarcasm) - so I'm spraying a light coat of oil over stuff and waiting for the sun after some de-rusting

1965 series 2a station wagon temporary brunox oil covering because of bad painting weather.JPG
 

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